Method and apparatus for installing geothermal heat exchanger

ABSTRACT

A borehole is bored to a borehole target depth in a site and a geothermal heat exchanger is inserted into and then secured in the borehole at the desired depth. Once the heat exchanger has been secured in the borehole, the heat exchanger has a closed distal end and an open proximal end and has at least one fluid path between the closed distal end and the open proximal end, with installation fluid disposed in the fluid path(s). After securing the heat exchanger in the borehole and before excavation of a portion of the site immediately surrounding the borehole, the heat exchanger is temporarily sealed by installing, through the open proximal end, at least one respective internal seal in each fluid path. For each fluid path, the internal seal(s) will be disposed below a respective notional subgrade depth and excavation of the site immediately surrounding the borehole can proceed.

TECHNICAL FIELD

The present invention relates to geothermal heat exchangers, and moreparticularly to installation of geothermal heat exchangers.

BACKGROUND

Geothermal heat exchangers are tubes (sometimes referred to as “loops”)that are installed underground and coupled to the heating and/or coolingsystem of a building (e.g. HVAC system). Fluid from the buildingheating/cooling system circulates in the tubes to exchange heat with thesurrounding underground substrate. Typically, there is a temperaturegradient between the ambient air and the underground substrate; thesubstrate is usually cooler than the air in summer and warmer than theair in winter. As such, the heat exchange can reduce the energy inputrequired to achieve climate control within the building.

A geothermal borehole is required prior to installation of a geothermalheat exchanger. For a geothermal heat exchanger installed below ayet-to-be-constructed building, the geothermal heat exchanger istypically installed after completion of excavation at the building site.This avoids the problem of having the loop interfere with excavation,and also avoids the risk of excavation debris entering the tube andobstructing fluid flow therethrough. However, this approach requiresthat construction operations, at least around the area of theborehole(s), be delayed during installation and testing of thegeothermal heat exchanger.

SUMMARY

In one aspect, the present disclosure describes a method of installing ageothermal heat exchanger. A borehole is bored to a borehole targetdepth in the site and, after boring the borehole, a geothermal heatexchanger is inserted into the borehole to a desired heat exchangerdepth and then secured in the borehole at the desired heat exchangerdepth. The heat exchanger may be, for example, a U-loop, such as asingle U-loop or a multiple U-loop, or may comprise at least an outertube of a concentric heat exchanger.

Once the heat exchanger has been secured in the borehole, the heatexchanger has a closed distal end and an open proximal end and has atleast one fluid path between the closed distal end and the open proximalend, with installation fluid disposed in the fluid path(s) of the heatexchanger. After securing the heat exchanger in the borehole and beforeexcavation of a portion of the site immediately surrounding theborehole, the heat exchanger is temporarily sealed between the closeddistal end and the open proximal end by installing, through the openproximal end, at least one respective internal seal in each fluid path.For each fluid path, the internal seal(s) will be disposed below arespective notional subgrade depth.

In one preferred implementation, after sealing the heat exchanger, theheat exchanger is cut above the uppermost seal(s) to produce at leastone above-seal cut portion of the heat exchanger above the uppermostseal(s), and each above-seal cut portion of the heat exchanger isremoved and the portion of the site immediately surrounding the boreholeis excavated above a lowermost notional subgrade depth. Optionally,after securing the heat exchanger in the borehole and before excavationof the site, the heat exchanger may be tested. After excavating theportion of the site immediately surrounding the borehole, the seals maybe removed for connection of the heat exchanger to supply/returnconduits. In some preferred embodiments, the installation fluid remainsin the heat exchanger during securing of the heat exchanger in theborehole and temporarily sealing the heat exchanger.

Cutting the heat exchanger and removing each above-seal cut portion ofthe heat exchanger may be carried out before excavation of the site orduring excavation of the site. In some embodiments, cutting is performedincidentally by excavating machinery during excavation of the portion ofthe site immediately surrounding the borehole.

Cutting the heat exchanger may be carried out by inserting a pipecutting tool into the open proximal end and then cutting the heatexchanger from the inside, for example by using a specialized pipecutting tool.

In another aspect, the present disclosure describes a pipe cutting tool.The pipe cutting tool comprises a main body having an axially-extendingouter guide surface adapted to guide the main body axially along aninside of a pipe along a pipe axis, with an arm recess in the guidesurface of the main body, and a cutting arm. The cutting arm has a pivotend that has a cam surface, a back-edge, a cutting edge and a cuttingend opposite the pivot end, with the cutting end having a cutting headdisposed along the cutting edge. The arm recess has a stop surfacedisposed therein, and the cutting arm is pivotally coupled at its pivotend to the main body within the arm recess so as to be pivotable,relative to the main body, about a pivot axis that is substantiallyparallel to the pipe axis. The cutting arm is pivotable between aretracted position in which the cutting arm is retracted into the armrecess so that the cutting edge faces the stop surface, and an extendedposition in which the cutting end of the cutting arm extends beyond theguide surface to expose the cutting head and the cam surface engages thestop surface to brace the cutting arm against force applied to thecutting head. A biasing member acts between the main body and thecutting arm to urge the cutting arm toward the extended position.

In some embodiments, a first axial end of the main body has an axiallyaligned drive rod recess that is threaded for threadedly receiving adrive rod. In some particular embodiments, the cutting arm is pivotallycoupled to the main body by a pivot pin passing through a pivot aperturein the pivot end of the cutting arm. A first end of the pivot pin isreceived in a pivot pin recess on a same axial side of the arm recess asthe drive rod recess. A second end of the pivot pin is received in abushing receptacle wherein a bushing is disposed in the bushingreceptacle on an opposite axial side of the arm recess from the driverod recess. The bushing is trapped in the bushing receptacle by asetscrew that is threadedly received in a setscrew recess on theopposite axial side of the arm recess from the drive rod recess.

The cutting head may be adapted to receive a blade facing the cuttingedge, or may have an integral blade facing the cutting edge.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features will become more apparent from the followingdescription in which reference is made to the appended drawings wherein:

FIG. 1A shows boring of a borehole, according to an aspect of thepresent disclosure;

FIGS. 1B and 1Ba show insertion of a geothermal heat exchanger into theborehole of FIG. 1A;

FIGS. 1C to 1E show securing the heat exchanger of FIGS. 1B and 1Ba inthe borehole of FIG. 1A;

FIG. 1F shows temporary sealing of the heat exchanger of FIGS. 1B and1Ba;

FIG. 1G shows cutting of the heat exchanger of FIGS. 1B and 1Ba abovethe uppermost seal(s) of FIG. 1F;

FIG. 1H shows removal of above-seal cut portions of the heat exchangerof FIGS. 1B and 1Ba;

FIGS. 1I and 1Ia show excavation of the portion of the site immediatelysurrounding the borehole of FIG. 1;

FIGS. 1J and 1K show removal of the seal(s) of FIG. 1F from the heatexchanger of FIGS. 1B and 1Ba;

FIGS. 1L and 1M show connection of heat exchanger of FIGS. 1B and 1Ba toan HVAC system;

FIG. 2A is a cross-sectional view of an illustrative closed-loopgeothermal heat exchanger having a single U-loop configuration;

FIG. 2B is a cross-sectional view of an illustrative closed-loopgeothermal heat exchanger having a double U-loop configuration;

FIG. 2C is a cross-sectional view of an illustrative closed-loopgeothermal heat exchanger having a concentric configuration;

FIG. 3A is a perspective view of an illustrative pipe cutting toolaccording to an aspect of the present disclosure, showing a cutting armthereof in a retracted position;

FIG. 3B is a perspective view of the pipe cutting tool of FIG. 3A,showing the cutting arm thereof in an extended position;

FIG. 3C is a cross-sectional view of the pipe cutting tool of FIG. 3A,taken along the line 3C-3C in FIG. 3B and shown inside a pipe;

FIG. 3D is a cross-sectional view of the pipe cutting tool of FIG. 3A,taken along the line 3D-3D in FIG. 3B and showing the cutting arm in aretracted position;

FIG. 3E is a cross-sectional view of the pipe cutting tool of FIG. 3A,taken along the line 3E-3E in FIG. 3B and showing the cutting arm in anextended position;

FIG. 3F is a top sectional view of the pipe cutting tool of FIG. 3A,showing the cutting arm in a retracted position;

FIG. 3G is a top sectional view of the pipe cutting tool of FIG. 3A,showing the cutting arm in an extended position;

FIG. 3H is a first side elevation view of the pipe cutting tool of FIG.3A, showing the cutting arm in a retracted position;

FIG. 3I is the same side elevation view as in FIG. 3H, showing thecutting arm in an extended position;

FIG. 3J is a second side elevation view of the pipe cutting tool of FIG.3A, showing the cutting arm in a retracted position; and

FIG. 3K is the same side elevation view as in FIG. 3J, showing thecutting arm in an extended position.

DETAILED DESCRIPTION

Reference is now made to FIGS. 1A to 1M, which show an illustrativemethod of installing a geothermal heat exchanger according to an aspectof the present disclosure.

Beginning with FIG. 1A, at a site 102, such as the substrate 104 uponwhich construction of a new building is planned, a borehole 106 is boredto a borehole target depth D in the site 102. In the illustratedembodiment, a hydraulic drill rig 110 is used to form the borehole 106.A hydraulic drill rig may be equipped, for example, with a single, dual,or sonic top drive.

Optionally, a casing (not shown) may be used to stabilize the overburden(usually made up of clays, sands, and gravels for the most part), and anopen hole (i.e. no casing) is drilled in the bedrock if encountered. Acasing may be installed following drilling overburden where air or mudrotary drilling is used, or a casing may be installed simultaneouslywith drilling of the overburden using a rig equipped with dual rotary orsonic top drive, or with an overburden drilling system. Casing used inconstruction of a geothermal borehole is normally temporary casing,meaning that it is removed following installation of the geothermal heatexchanger into the borehole. The casing size must be large enough toaccommodate the drill bit size used to drill the bedrock below; commonsizes include 133 mm outside diameter (OD) (5.5″) and 165 mm OD (6.5″).Bedrock is normally drilled with either down-the-hole hammer (for hardrock such as granite), or with PDC bits (for softer sedimentary rock).The fluid used to drill the rock is often compressed air but water ormud rotary drilling can also be used. Mud rotary drilling may also beused to drill an open hole in overburden, usually to a maximum depth of150 metres and more frequently to depths of less than 100 metres. Mudrotary drilling of an open hole is not commonly used to greater depthsbecause it becomes very difficult to maintain hole stability and to getthe geothermal heat exchanger to the target depth. The borehole size isdictated by heat exchanger geometry and grouting requirements. Typicalminimum borehole size for a 32 mm (1.25″) single U-loop heat exchangeris 98 mm and for a 38 mm (1.5″) single U-loop heat exchanger is 108 mm.Larger hole sizes are often used due to typical tooling of drillingequipment and 152 mm (6″) is very common among water well drillingequipment. Boreholes are typically vertical but can be drilled in on anangle or directionally drilled using steerable drilling technology.

Selection of the drilling approach depends on geology, availability ofequipment, target depth of the geothermal heat exchanger, and regulatoryrequirements, and is within the capability of one skilled in the art.

Referring now to FIG. 1B and FIG. 1Ba, after boring the borehole 106, ageothermal heat exchanger 112 is inserted into the borehole 106 to adesired heat exchanger depth, which may be the same as or slightly abovethe borehole depth D.

The geothermal heat exchanger 112 is typically in the form of one ormore tubular pipes in a U-shaped configuration (referred to as a“U-loop”). The most common closed-loop geothermal heat exchangerconfiguration is a single U-loop, as shown in FIG. 2A, which consists oftwo pipes 114 joined by a 180-degree elbow fitting 118 at the distal endof the heat exchanger 112 so as to form two continuous parallel arms 116extending the length of the heat exchanger 112. Double U-loopconfigurations, as shown in FIG. 2B, are common in Europe, with twopairs of pipes 114A, 114B each joined by a respective 180-degree elbowfitting 118A, 118B to form two respective pairs of parallel arms 116A,116B. Thus, in a double-U-loop configuration, there are four continuousparallel arms 116A, 116B running the length of the heat exchanger 112with a double 180-degree elbow 118A, 118B at the distal end of the heatexchanger 112. In another embodiment, as shown in FIG. 2C, an alternateform of geothermal heat exchanger 212 may be a concentric or coaxialheat exchanger comprising an outer tube 214 and an inner tube 216 influid communication with one another, with the outer tube 214 having aclosed distal end 218 and the inner tube 216 having an open distal endthat terminates short of the closed distal end 218 of the outer tube214. Where a concentric heat exchanger 212 is used, optionally only theouter tube 214 need be inserted at the step shown in FIGS. 1B and 1Ba.Other configurations are available but less common such as various pipecross sections that are not necessarily round (e.g. GI4™), and multipleU-loops may have more than two pipes (e.g. Twister™).

Common U-loop pipe sizes range of ¾″ IPS to 1.5″ IPS with wall thicknessfrom SDR9 to SDR13.5 (SDR is the pipe diameter to wall thickness ratio).The most common pipe material is high density polyethylene, such as HDPE3608 or HDPE 4710 although some other materials or thermally enhancedHDPE are used occasionally.

In each case, that is, whether a U-loop heat exchanger 112, a concentricheat exchanger 212 or another configuration, the heat exchanger has aclosed distal end (e.g. the elbow(s) 118, 118A, 118B or the closed end218 of the outer tube 214).

Returning to FIG. 1B and FIG. 1Ba, it will be seen that the illustrativegeothermal heat exchanger 112 is a single U-loop heat exchanger 112comprising a flexible pipe 114 whose elbow 118 forms the closed distalend.

Insertion of the geothermal heat exchanger 112 into the borehole 106 maybe carried out manually, as shown in FIG. 1B, or with a mechanicalsystem 120, as shown in FIG. 1Ba. Larger pipe diameters (e.g. 1.25″ and1.5″) and deep boreholes usually make mechanical insertion necessary.Both manual and mechanical insertion are within the capability of oneskilled in the art.

After inserting the heat exchanger 112 into the borehole 106, the heatexchanger 112 is secured in the borehole 106 at the desired heatexchanger depth. The annular space 128 (see FIGS. 1C to 1E) between theheat exchanger 112 and the wall of the borehole 106, as well as anyspace 130 between the arms 116 of the heat exchanger 112, is normallygrouted using bentonite-based or cement-based grouts, withbentonite-based grouts being more common because of ease of use andimproved performance. Thermal enhancement material is commonly used withbentonite-based grout to improve heat exchanger performance. Thesematerials are typically silica sand and more recently, graphitematerial. Before introduction of the grout, the heat exchanger 112 isfilled with an installation fluid 115 (such as water) maintained at asuitable pressure to maintain the structural integrity of the pipe 114(i.e. prevent inward collapse).

To apply the grout, a tremie line 122 is inserted into the borehole 106.Typically, the pipe 114 and tremie line 122 will be fed off ofrespective coils 124, 126 and inserted at the same time (see FIGS. 1Band 1Ba). The tremie line 122 may also be placed into the boreholefollowing the insertion of the heat exchanger 112 into the borehole 106.As can be seen in FIGS. 1C to 1E, with a U-loop configuration the tremieline 122 is typically positioned between the arms 116 of the heatexchanger 112.

At commencement of grouting, the outlet end 132 of the tremie line 122is initially positioned near the distal end of the heat exchanger, asshown in FIG. 1C. The elbow 118 of the heat exchanger 112 may rest on asupport 134 as shown, which support may double as a plumb-weight, or theelbow 118 of the heat exchanger 112 may rest directly on the bottom ofthe borehole 106, or the heat exchanger 112 may simply be suspended inthe borehole 106 while the grout is applied.

Grout 136 is injected into the borehole 106, as shown in FIG. 1D, untilthe outlet end 132 of the tremie line 122 is submerged in the grout 136several metres below the surface or meniscus of the grout 136. In thisway, the grout 136 will push any water or other material out of theborehole 106, resulting in a continuous column of grout in the borehole106. As the borehole 106 is grouted, the tremie line 122 is pulled backout of the borehole while keeping the outlet end of the tremie line 122submerged in the grout 136 until the borehole 106 is substantiallyfilled, as shown in FIG. 1E. After the grout 136 has set, the excesslength of the arms 116 of the pipe 114 that protrude beyond the mouth ofthe borehole 106 can be cut so that they are approximately flush withthe surface of the substrate 104 in which the borehole 106 is formed, soas to provide the heat exchanger 112 with an open proximal end 138, asshown in (e.g.) FIG. 1F. Alternatively, although less preferred, thepipe 114 can be pre-cut so that it will have a length corresponding tothe depth of the borehole 106, or may be cut before grouting.

Where casing is used, grout is placed in the casing immediately prior topulling the casing such that the grout has not yet ‘set up’ or stiffenedso that the grout slumps out of the casing as it is pulled out of theborehole. As casing is pulled, grout is then used to top up the boreholeso that the borehole is completely filled with grout once all casing hasbeen extracted from the ground.

Once the heat exchanger 112 has been inserted and the borehole 106 hasbeen grouted (or the heat exchanger 112 is otherwise secured in theborehole 106), the integrity of the heat exchanger 112, the depth of theheat exchanger 112, and potentially the quality of the grout 106 aroundthe heat exchanger 112 may all be tested. Testing the depth and groutquality requires access to the heat exchanger 112 from the surface 104of the site 102 to the full depth. Pressure testing also requiressurface access and hydraulic continuity, but it does not necessarilyrequire access to the bottom of loop, thereby allowing internal seals orplugs to be placed at some depth within the heat exchanger. The abovetesting is within the capability of one skilled in the art, now informedby the present disclosure. Thus, after securing the heat exchanger 112in the borehole 106, the usual testing of the heat exchanger 112 can becarried out before excavation of the portion 140 (FIG. 1I) of the site102 immediately surrounding the borehole 106.

As noted above, the heat exchanger has a closed distal end (e.g. theelbow(s) 118, 118A, 118B or the closed end 218 of the outer tube 214)and, at least after being secured in the borehole 106 afterinstallation, has an open proximal end 138 (e.g. the ends of the pipe(s)114, 114A, 114B distal from the elbow(s) 118, 118A, 118B or the end of(at least) the outer tube 214 remote from the closed distal end 218).The open proximal end 138 is proximal to the surface of the substrate104 of the site 102. The heat exchanger 112 also has at least one fluidpath between the closed distal end 118, 118A, 118B and the open proximalend 138 (e.g. provided by the pipe(s) 114, 114A, 114B, 214, 216).

Following insertion (FIGS. 1B/1Ba), grouting (FIGS. 1C to 1E), andtesting, internal seals (e.g. plugs) can be placed in the heat exchanger112 from the open proximal end 138 at one or more notional subgradedepths to inhibit debris from entering the heat exchanger 112. The term“notional subgrade depth”, as used herein, refers to a depth below whichno construction excavation is anticipated, at least within the portion140 of the site 102 immediately surrounding the borehole 106. As aprecaution, there may be multiple notional subgrade depths, with sealsbeing placed below each, as described further below. The optionalprovision of additional notional subgrade depth(s) could account for theneed to excavate deeper than expected due to construction exigencies,errors by operation of the construction equipment, etc. While optionallyseals could be placed below only the lowermost notional subgrade depth,this increases the risk that debris will enter the heat exchanger abovethe seals.

Referring now to FIG. 1F, after securing the heat exchanger 112 in theborehole 106 and before excavation of a portion 140 (see FIG. 1I) of thesite 102 immediately surrounding the borehole 106, the heat exchanger112 is temporarily sealed. The term “portion of the site immediatelysurrounding the borehole”, as used herein, refers to the region (portionof the site) that is within five meters, preferably within three metersand more preferably within one meter of the borehole 106, measuredradially from the outer circumference of the borehole 106. Excavation ofother portions of the site 102, i.e. those other than the portion 140 ofthe site 102 immediately surrounding the borehole 106, may be carriedout before temporarily sealing the heat exchanger 112. Thus, otherconstruction activities may proceed on other parts of the site 102during, for example, formation of borehole 106, installation of the heatexchanger 112 and grouting of the heat exchanger 112, before temporarilysealing the heat exchanger 112.

Continuing to refer to FIG. 1F, the heat exchanger 112 is temporarilysealed between the closed distal end 118 (or 118A, 118B, 218) and theopen proximal end 138 by installing, through the open proximal end 138,at least one respective internal seal in each fluid path, e.g. thepipe(s) 114 (or 114A, 114B, 214, 216). The internal seals may take awide variety of forms, and may have a shape adapted to the particulartype of heat exchanger. For example, and without limitation, an internalseal may comprise one or more of a compressible foam ball plug 142 asshown in the main portion of FIG. 1F, a compressible foam cylinder plug142A as shown in the lower right side enlargement in FIG. 1F, or a gelplug 142B as shown in the upper right side enlargement in FIG. 1F, eachof which is described further below. Each of the seals (e.g. ball plugs142) is disposed below a respective notional subgrade depth 144A, 144B,144C.

As noted above, in some embodiments, there may be multiple notionalsubgrade depths, with seals being placed at each. For example, it may beexpected that excavation will not continue below (e.g.) 10 meters fromthe surface 104, which would be a first notional subgrade depth 144A,but a second notional subgrade depth 144B of (e.g.) 10.5 meters and athird notional subgrade depth 144C of (e.g.) 11 meters may also beprovided. These are merely examples of subgrade depths and are notintended to be limiting. Seals (e.g. ball plugs 142) are disposedbetween the first notional subgrade depth 144A and the second notionalsubgrade depth 144B, between the second notional subgrade depth 144B andthe third notional subgrade depth 144C, and below the third notionalsubgrade depth 144C. Hence, there are seals (e.g. ball plugs 142)disposed beneath each of the first notional subgrade depth 144A, thesecond notional subgrade depth 144B and the third notional subgradedepth 144C. Any desired number of notional subgrade depths andassociated seals may be provided.

Still referring to FIG. 1F, the compressible foam ball plugs 142 may beplaced below the desired subgrade depth 144A, 144B, 144C by forcing themalong the interior of the pipes 114 using a rod 146 having depthmarkings 148.

As described above, in some embodiments, one or more seals may comprisea compressible foam cylinder 142A. The compressible foam cylinder plug142A may simply be forced into position using the rod 146 similarly tothe ball seals (e.g. ball plugs 142), or be compressed and vacuum-sealedinside an air-impermeable barrier membrane so as to form a compressed“packet” that can easily fit within the interior of the pipe 114. Thispacket can then be lowered to the desired depth and then the barriermembrane can be ruptured to permit the cylinder plug 142A to expandagainst the interior wall of the pipe 114.

As also mentioned above, in some embodiments, one or more seals maycomprise a gel plug 142B. A gel plug 142B may comprise a sealedwater-soluble tube filled with water absorbent yarn. The water solubletube can be lowered to the desired depth and suspended in place using astring line. The water-soluble tube remains in place until it isdissolved, which then allows water to reach the water absorbent yarn.The yarn expands to fill the interior of the pipe 114 and provide a gelplug over a desired interval.

Reference is now made to FIG. 1G. After sealing the heat exchanger 112,the heat exchanger 112 is cut above the uppermost seal(s) 142. It willbe appreciated that cutting the heat exchanger 112 above the uppermostseal(s) 142 means that the heat exchanger 112 is also cut above thelowermost seal(s) since the uppermost seal(s) 142 will necessarily beabove the lowermost seal(s) 142. In the illustrated embodiment, each ofthe arms 116 of the pipe 114 is cut above the ball seals (e.g. ballplugs 142) positioned immediately below the first notional subgradedepth 144A. Cutting of the heat exchanger 112 may be carried out usingany suitable technique; preferably, as shown in FIG. 1G, the cutting iscarried out by inserting a specialized pipe cutting tool 300 into theopen proximal end 138 and cutting the heat exchanger 112 (e.g. cuttingthe arms 116 of the pipe 114) from the inside. As shown in the enlargedportion of FIG. 1G, the illustrative pipe cutting tool 300 comprises amain body 302 and a retractable cutting arm 304 and can be mounted onthe end of the depth-marked rod 146 so that it can be advanced to thedesired depth. The illustrative pipe cutting tool 300 will be describedin more detail below.

Referring now to FIG. 1H, cutting of the heat exchanger 112 produces twoabove-seal cut portions 150 (one for each arm 116 of the pipe 114) ofthe heat exchanger 112. (In the case of a co-axial heat exchanger, theremay be only a single cut portion, and in the case of a multiple-U-loopheat exchanger, there would be more than two cut portions.) The cutportions 150 are located above the uppermost seals, hence the term“above-seal”; in the illustrated embodiment this is above the ball seals(e.g. ball plugs 142) positioned immediately below the first notionalsubgrade depth 144A. The cut portions 150 of the heat exchanger 112 arethen removed from the borehole 106, e.g. by mechanical or manualpulling, leaving only the grout 136 above the position where the heatexchanger 112 was cut.

Thus, in the embodiment shown in FIGS. 1H and 1I, cutting the heatexchanger 112 and removing each above-seal cut portion 150 of the heatexchanger 112 is carried out before excavation of the portion 140 of thesite 102 immediately surrounding the borehole 106.

Turning to FIG. 1I, after cutting the heat exchanger 112 above theuppermost seal(s) and removing the above-seal cut portions 150 of theheat exchanger 112, excavation of the portion 140 of the site 102immediately surrounding the borehole 106 can proceed. By cutting theheat exchanger 112 and removing the above-seal cut portions 150 prior toexcavation, construction work can proceed without interference from heatexchanger piping. If it should become necessary to excavate to (e.g.)the second notional subgrade depth 144B or the third notional subgradedepth 144C, the cutting procedure can be repeated above the ball plugs142 (or other seals) above the respective notional subgrade depth.

Alternatively, in some embodiments cutting the heat exchanger 112 andremoving each above-seal cut portion 150 of the heat exchanger 112 maybe carried out during excavation of the portion 140 of the site 102immediately surrounding the borehole 106. More particularly, dependingon the material from which the heat exchanger 112 is constructed, it maybe more efficient and cost effective to allow portions above the seals(i.e. above seal cut portions 150) to be severed and removed by theexcavation process itself (e.g. by construction equipment such as anexcavator, bulldozer, backhoe, etc.). Thus, cutting may be performedincidentally by excavating machinery 152 during excavation of theportion 140 of the site 102 immediately surrounding the borehole 106.This process is shown in FIG. 1Ia. If it is necessary to excavate belowthe first notional subgrade depth 144A to (e.g.) the second notionalsubgrade depth 144B or the third notional subgrade depth 144C,excavation can continue as long as the heat exchanger is not cut belowthe lowermost notional subgrade depth (i.e. excavation remains above thelowermost of the seal(s) 142 in the heat exchanger 112).

In either case (removal of above-seal cut portion 150 before excavationor during excavation), after completing excavation of the portion 140 ofthe site 102 immediately surrounding the borehole 106, the seals (e.g.ball plugs 142) can then be removed, as shown in FIGS. 1J and 1K. As canbe seen in the Figures, in preferred embodiments the installation fluid115 remains in the heat exchanger 112 during securing of the heatexchanger 112 in the borehole 106, and through temporarily sealing ofthe heat exchanger 112, cutting of the heat exchanger 112 and excavationof the portion 140 of the site 102 immediately surrounding the borehole106. As such, removal of the seals (e.g. ball plugs 142) can be achievedby supplying pressurized fluid, denoted by arrow 154 in FIG. 1K, at theopen end 138 of one arm 116 of the heat exchanger 112 which will thenforce the ball plugs 142 (or other seals) out of the open end 138 of theother arm 116 of the heat exchanger 112. Thus the seals (e.g. ball plugs142) can be removed for connection of the heat exchanger 112 tosupply/return conduits 156, for example of an HVAC system 158 in amechanical room 160 of a multi-level parking garage 162, as shown inFIGS. 1L and 1M. This permits a heat exchanger fluid (e.g. water withcorrosion inhibitor and antifreeze such as ethanol or propylene glycol),shown by arrows 166, to be passed from the HVAC system through the heatexchanger 112.

Reference is now made to FIGS. 3A to 3K, which show the illustrativepipe cutting tool 300 in more detail. As noted above, the illustrativepipe cutting tool 300 comprises a main body 302 and a cutting arm 304.The main body 302 has an axially-extending outer guide surface 306adapted to guide the main body 302 axially along the inside of a pipe308 (FIGS. 3C to 3E) along a pipe axis PA (FIGS. 3A to 3B). The pipeaxis PA corresponds to the longitudinal extent of the pipe 308. In theillustrated embodiment the main body 302 is substantially cylindricalwith tapered ends although other shapes are contemplated; in otherembodiments the guide surface may include bearings adapted to engage theinside of the pipe.

One axial end of the main body 302 has an axially aligned drive rodrecess 310 (see FIGS. 3D and 3E) that is threaded for threadedlyreceiving a drive rod, such as the depth-marked rod 146, for driving thepipe cutting tool 300 along the inside of the pipe 308.

An arm recess 312 is formed in the guide surface 306 of the main body302 to receive the cutting arm 304, and a stop surface 314 is disposedin the arm recess 312. The cutting arm 304 has a pivot end 316 and acutting end 318 opposite the pivot end 316, with a back-edge 320 and acutting edge 322 extending between the pivot end 316 and the cutting end318. The back-edge 320 and a cutting edge 322 are generally opposed toone another. The pivot end 316 has a cam surface 324 and the cutting end318 has a cutting head 326 disposed along the cutting edge 322. Thecutting head 326 carries a blade 328 facing the cutting edge 322. Thecutting head 326 may be adapted to receive a replaceable blade, or mayhave an integral blade, in which case the cutting head itself may bereplaceable. Alternatively, the entire cutting arm 304 may be replacedif the blade 328 becomes dull.

The cutting arm 304 is pivotally coupled at its pivot end 316 to themain body 302 within the arm recess 312 so as to be pivotable, relativeto the main body 302, about a pivot axis P that is substantiallyparallel to the pipe axis PA. The pivot axis P of the cutting arm 304 islaterally offset from a central rotational axis R of the main body 302that is, when the cutting tool 300 is inside the pipe 308, parallel to,and typically coincident with, the pipe axis PA. Thus, the pivot axis Pof the cutting arm 304 will be laterally offset from the pipe axis PA.The cutting arm 304 can pivot between a retracted position, as shown inFIGS. 3A, 3D, 3F, 3H and 3J, and an extended position, as shown in FIGS.3B, 3C, 3E, 3G, 3I and 3K. In the retracted position, the cutting arm304 is retracted into the arm recess 312 so that the cutting edge 322faces and may engage the stop surface 314. In the extended position, thecutting end 318 of the cutting arm 304 extends beyond the guide surface306 to expose the cutting head 326 and the blade 328 and the cam surface324 on the pivot end 316 engages the stop surface 314 to brace thecutting arm 304 against force applied to the cutting head 326 on thecutting edge side thereof (i.e. against pressure applied to the blade328).

As best seen in FIGS. 3D and 3E, in the illustrated embodiment, thecutting arm 304 is pivotally coupled to the main body 302 by a pivot pin330 passing through a pivot aperture 332 in the pivot end 316 of thecutting arm 304. One end 334 of the pivot pin 330 is received in a pivotpin recess 336 on the same axial side of the arm recess 312 as the driverod recess 310 and the other end of the pivot pin 330 is received in abushing receptacle 340. A bushing 342 (or alternatively a bearing suchas a needle bearing) is disposed in the bushing receptacle 340 on theopposite axial side of the arm recess 312 from the drive rod recess 310,and the other end of the pivot pin 330 is journalled in the bushing 342.The bushing 342 is maintained in the bushing receptacle 340 by asetscrew 344 that is threadedly received in a setscrew recess 346 on theopposite axial side of the arm recess 312 from the drive rod recess 310.More particularly, the setscrew 344 traps the bushing 342 against abushing shoulder 348.

A biasing member acts between the main body 302 and the cutting arm 304to urge the cutting arm 304 toward the extended position. In theillustrated embodiment, the biasing member takes the form of a coilspring 350. The coil spring 350 surrounds the pivot pin 330; with oneterminal arm of the coil spring 350 engaging the main body 302 and theother terminal arm of the coil spring 350 engaging the cutting arm 304.

In operation, the cutting arm 304 is placed into the retracted position,and the cutting tool 300 is inserted into the inside of the pipe 308.Despite the force exerted by the coil spring 348, as long as the cuttingtool 300 is advanced axially along the pipe 308 without rotation, thewall of the pipe 308 will maintain the cutting arm 304 substantially inthe retracted position. More particularly, the back-edge 320 of thecutting arm 304 will engage the inner surface 350 of the pipe 308, sothat even if the cutting arm 304 moves slightly of the fully retractedposition, the cutting arm 304 cannot move fully into the extendedposition and the cutting edge side of the cutting head 326 having theblade 328 is not exposed. Moreover, while advancing the cutting tool 300along the pipe 308, rotating the main body 302 in the same directionthat the cutting arm 304 pivots from the retracted position to theextended position can assist in preventing the cutting arm 304 frompivoting into the extended position.

Once the cutting tool 300 has been advanced to the desired position inthe pipe 308, the cutting arm 304 can be moved into the extendedposition by rotating the main body 302 opposite to the direction thatthe cutting arm 304 pivots from the retracted position to the extendedposition, as shown by arrow 352 in FIGS. 3E and 3F. Because the pivotaxis P is laterally offset from the central rotational axis R of themain body 302, this rotation will allow the cutting arm 304 to pivot,under urging from the coil spring 348, toward the extended position inwhich the cutting head 326 and the blade 328 are exposed. This is shownby arrow 354 in FIG. 3G. Once the cutting arm 304 reaches the extendedposition and is braced by the engagement of the cam surface 324 with thestop surface 314, continued rotation of the main body 302 will cause theblade 328 to cut into the pipe 308, as shown in FIGS. 3C and 3E.Rotation of the main body 302 can continue until the blade 328 hascompletely traversed the circumference of the pipe 308 so as to severthe pipe 308. The extended cutting arm 304 then acts as a hook to allowthe upper portion of the severed pipe 308 (e.g. above-seal cut portion150) to be pulled up and away.

Certain illustrative embodiments have been described by way of example.It will be apparent to persons skilled in the art that a number ofvariations and modifications can be made without departing from thescope of the claims.

What is claimed is:
 1. A method of installing a geothermal heatexchanger, the method comprising: at a site, boring a borehole to aborehole target depth in the site; after boring the borehole, insertinga geothermal heat exchanger into the borehole to a desired heatexchanger depth, after inserting the heat exchanger into the borehole,permanently securing the heat exchanger in the borehole at the desiredheat exchanger depth; wherein, when the heat exchanger has beenpermanently secured in the borehole: the heat exchanger has a closeddistal end and an open proximal end; the heat exchanger has at least onefluid path between the closed distal end and the open proximal end; andinstallation fluid is disposed in the at least one fluid path of theheat exchanger; and after permanently securing the heat exchanger in theborehole, before cutting the heat exchanger and while the heat exchangerremains permanently secured in the borehole, and before excavation of aportion of the site immediately surrounding the borehole, temporarilysealing the heat exchanger between the closed distal end and the openproximal end by installing, through the open proximal end, at least onerespective internal seal in each fluid path, wherein for the at leastone fluid path, the at least one internal seal is disposed below arespective notional subgrade depth.
 2. The method of claim 1, furthercomprising: after sealing the heat exchanger, while the heat exchangerremains permanently secured in the borehole, cutting the heat exchangerabove an uppermost one of the at least one seal to produce at least oneabove-seal cut portion of the heat exchanger; after cutting the heatexchanger, removing each above-seal cut portion of the heat exchanger;the method further comprising-excavating the portion of the siteimmediately surrounding the borehole; wherein excavating the portion ofthe site immediately surrounding the borehole is above a lowermost ofthe notional subgrade depth; and after excavating the portion of thesite immediately surrounding the borehole, removing the seals forconnection of the heat exchanger to supply/return conduits.
 3. Themethod of claim 2, wherein cutting the heat exchanger and removing eachabove-seal cut portion of the heat exchanger is carried out beforeexcavation of the site.
 4. The method of claim 2, wherein cutting theheat exchanger is carried out by inserting a pipe cutting tool into theopen proximal end and cutting the heat exchanger from the inside.
 5. Themethod of claim 2, wherein cutting the heat exchanger and removing eachabove-seal cut portion of the heat exchanger is carried out duringexcavation of the site.
 6. The method of claim 5, wherein cutting isperformed by use of a pipe cutting tool, comprising: a main body havingan axially-extending outer guide surface adapted to guide the main bodyaxially along an inside of a pipe along a pipe axis; an arm recessformed in the guide surface of the main body, the arm recess having astop surface disposed therein; and a cutting arm having: a pivot end,the pivot end having a cam surface; a back-edge; a cutting edge; and acutting end opposite the pivot end, the cutting end having a cuttinghead disposed along the cutting edge; the cutting arm being pivotallycoupled at its pivot end to the main body within the arm recess so as tobe pivotable, relative to the main body, about a pivot axis that issubstantially parallel to the pipe axis, between: a retracted positionin which the cutting arm is retracted into the arm recess so that thecutting edge faces the stop surface; and an extended position in which:the cutting end of the cutting arm extends beyond the guide surface toexpose the cutting head; and the cam surface engages the stop surface tobrace the cutting arm against force applied to the cutting head; and abiasing member acting between the main body and the cutting arm to urgethe cutting arm toward the extended position.
 7. The method of claim 5,wherein cutting is performed by excavating machinery during excavationof the portion of the site immediately surrounding the borehole.
 8. Themethod of claim 1, further comprising: after securing the heat exchangerin the borehole and before excavation of the site, testing the heatexchanger.
 9. The method of claim 1, wherein the installation fluidremains in the heat exchanger during securing of the heat exchanger inthe borehole and temporarily sealing the heat exchanger.
 10. The methodof claim 1, wherein the heat exchanger is a U-loop.
 11. The method ofclaim 10, wherein the heat exchanger is a single U-loop.
 12. The methodof claim 10, wherein the heat exchanger is a multiple U-loop.
 13. Themethod of claim 1, wherein the heat exchanger is at least an outer tubeof a concentric heat exchanger.